ProcessesMIG (GMAW)Flux-cored (FCAW) Submerged arc (SAW)Stick (SMAW) TIG (GTAW) Air carbon arc (CAC-A) cutting and gouging Rated: 3/8-inch carbons

Heavy Industrial ApplicationsFabrication and constructionHeavy manufacturingMRO — maintenance/repairPressure tank/vessel fabricationShipbuildingRefineries and foundriesRailcar manufacturingEarth-moving equipment manufacturing

Issued March 2016 • Index No. DC/19.3

Input Power 3-phase power 380/460 V, 50/60 Hz

Rated Output 650 A at 44 VDC, 100% duty cycle

Output Range 15–815 A, 10–65 V

Net Weight 158 lb. (71.7 kg)

ArcReach (recommended option)Remote voltage control without a control cable

Multiprocess Welding Power Source Dimension™650

QuickSpecs

Power source is warranted for three years, parts and labor.Original main power rectified parts are warranted for five years.

Rugged and durableinside and out

BUILTTO LAST

Power and precision

POWERFOR THICKMETALS

PRECISIONFOR THIN METALS

Improved weld quality

BETTERWELDSWITH LESSREWORK

More portable and takes up less floor space

An unbeatable combination ofdurability, output, efficiency andcapability — all in a smaller,easier-to-handle package. Insideits tough, corrosion-resistant,all-aluminum case is big powerfor heavy welding jobs andcarbon arc gouging.

In addition to excellent stick andLift-Arc™ TIG, the Dimension 650also has excellent short-arc MIGcharacteristics for precise thin-metal welding performance.

Big capabilities in a smaller package.

Developed for harsh environmental conditions and outputrequirements that range from power-intensive to precise.

Miller Electric Mfg. Co.An ITW Welding Company1635 West Spencer StreetP.O. Box 1079Appleton, WI 54912-1079 USA

MillerWelds.comEquipment Sales US and CanadaPhone: 866-931-9730FAX: 800-637-2315International Phone: 920-735-4554International FAX: 920-735-4125

ArcReach™ — remote control without a cord

PRODUCTIVITY

QUALITYSAFETY

2

Dimension™ 650 Advantages

All-aluminum construction helps the machine resistcorrosion for long life.

Exclusive protection input inductor protects machine’sperformance and reliability from “dirty” input power.

Wind Tunnel Technology.™ Internal air flow that protectselectrical components and PC boards from dirt, dust,debris... greatly improving reliability

Fan-On-Demand™ operates only when needed reducingnoise, power consumption, and the amount of airbornecontaminants pulled through the machine.

Reduced size and weight results in an easier-to-handlepackage that exceeds the welding performance of larger,heavier machines. Weighing in at 158 pounds (71.7 kg), theDimension 650 is 3.5 times lighter than the Dimension 652,making it easier to move around the shop, jobsite, orshipyard. It also uses 40-percent less floor space.

Withstands harsh environments

Smaller and lighter

Rugged and durableinside and out

BUILTTO LAST

More portable and takes up less floor space

High electrical efficiency and excellent power factormean that you can get more welding done using lesspower. On 460 V, the Dimension 650 draws only 43 ampsat rated load and can operate on a 50-amp service. Fourmachines can work at maximum loads simultaneously on a 200-amp service, drawing less amperage than threeprevious models.

Power efficient

Uses 32% fewer ampsthan previous model

93%EFFICIENT

Current model

Current model

Previous model

Previous model

3.25 in.

3.25 inches ofground clearancekeeps the machineaway from water,mud and dirt toprotect interiorcomponents.

40% smallerfootprint Dimension 650 footprint

Dimension 652 footprint

Four Dimension 650s

draw less power –only 172 amps

Three Dimension 652sdraw 189 amps

3

Dimension™ 650 Advantages

High-quality performance from power-intensive toprecise. Knowing quality welds begin with a quality arc,we’ve significantly improved the performance in all weldingprocesses and made it easy to fine tune the arc to matchyour personal preferences and welding style.

Gouging mode provides 800 amps of usable power, a full650 amps of power at 100-percent duty cycle. Perfect forheavy gouging with 3/8-inch carbons.

Three wire modes (GMAW/FCAW/SAW) for simplifiedsetup and optimized arc performance.• Solid and flux-cored wires with gas offer exceptional

short-arc MIG precision to weld thin metals with less riskof distortion or burn-through, and premium flux-coredwelding with gas.

• Flux-cored (self-shielded) welding performance isexceptional, especially with wires commonly found ininfrastructure construction.

• Sub arc mode provides capability to retrofit into non-digital sub arc applications.

Excellent stick and Lift-Arc™ TIG performance.

Arc control is beneficial when welding with stick and solidwires for easier fine-tuning of tough-to-weld materials andout-of-position applications.

Improved arc performance

Power and precision

POWERFOR THICKMETALS

PRECISIONFOR THIN METALS

Improved weld quality

BETTERWELDSWITH LESSREWORK

Weld process switch withGouge mode, three Wiremodes, Stick mode and Lift-Arc TIG mode.

Arc control for additionalfine-tuning in Stick orSolid Wire modes.

Dimension™ 650 Recommended Option

Remote control of the power source without a cord. An ArcReach system allows you to change weld settings from your SuitCase wire feeder or stick/TIG remote, saving a trip to the power supply. ArcReach technology uses the existing weld cable tocommunicate welding control information between the feeder or remote and the powersource. This technology eliminates the need for control cords, and their associatedproblems and costs.

ArcReachpower source

ArcReachSuitCase feeder

or stick/TIGremote

For MIG or flux-coredwelding — SuitCase X-TREME 8VS/12VSArcReach feeders• Remote voltage control• Polarity indication• Auto-Process Select™

For stick or TIG welding — ArcReach stick/TIG remote• Remote amperage control• Arc control for stick• Polarity indication• Auto-Process Select™

ArcReach accessories

4

Specifications (Subject to change without notice.)

Rated Output

650 A at 44 VDC,100% duty cycle

Amperage/Voltage Ranges

15–815 A in CC mode10–44 V in CV mode10–65 V in SAW mode

Max. Open-Circuit Voltage

87

Amps Input at Rated Output, 50/60 Hz380 V 460 V KVA KW

53.2 42.8 34 30.7

Dimensions

H: 28.187 in. (716 mm)(including lift eye)W: 16.687 in. (424 mm)D: 31.625 in. (803 mm)

Net Weight

158 lb.(71.7 kg)

Dimension™ 650 Features

Standard 14-pin receptacle withAuto-Remote Sense™ for simpleconnection of remote controls andwire feeders.

Front-panel-mounted power switchis easy to access when in racks ormanufacturing cells.

Durable weld cable connections• Serrated hardware for single-wrench

application• Easy double weld cable installation• Flexible, protective covers prevent

incidental contact

Back panel. 20 amps of 120 V powerto run power tools — like grinders,chop saws, drills and lights.

LED process indicator. Front panelprocess selections are illuminated with an LED that identifies the activeprocess. This enables the selectedweld process to be seen at a distancefrom the power source.

• Gouging mode is an optimized stick position for better gougingperformance

• Three wire modes(GMAW/FCAW/SAW) for simplifiedsetup and optimized arc performance- Solid and flux-cored wires with gas- Flux-cored (self-shielded)- Sub arc

• Stick mode for all electrode types• Lift-Arc™ TIG

Digital meters with SunVision™ technology enable weldingparameters to be viewed with greater clarity than analogmeters — at virtually any angle. Meters can be seen clearlyeven in direct sunlight.Meters display• Process settings for quick and easy setup• Preset and actual amperage

Arc control is active in the stick andsolid-wire processes. It allows theoperator to customize arc characteristicsto match preference, electrode and jointdesign from a softer arc with more fluidpuddle to a stiffer arc with an morecontrollable puddle. The Star setting is optimized for most applications and pointing the control at Soft or Stiff is optimal for most arc preferences.Control is fully adjustable from 0 to 25Soft or 0 to 25 Stiff.

Dimension 650 ArcReachadditional featuresRemote in use indicator providesconvenient feedback indicating anArcReach wire feeder is controllingthe power source. While underArcReach control, process andvoltage/amperage adjustments arelocked out, preventing accidentalchanges by personnel other than thewelding operator.

NEW! Auto-Bind automaticallyestablishes an exclusive communi -cation between the power source andthe wire feeder, using the existingweld cables upon system power up.

Fleet compatibility. ArcReach-equipped power sources and wirefeeders work with non-ArcReachequipment; however, the completeArcReach benefit is only realizedwith the ArcReach system.

Remote in use indicator. Onstandard Dimension 650 modelsthe remote in use indicator meansa device (remote control or wirefeeder with a remote control) isconnected to the 14-pin connector.

5

Wire Feeder Options

Bench-Style Feeders20 Series Feeders See literature M/11.022A and 24A — Simple and cost-effective feeders for industrial manufacturing andfabricating.

70 Series Feeders See literature M/3.074S — Standard, simple feeders for most heavy-industrial applications.74D — Provides increased accuracy and control of the most common weld parameters.74DX — Provides added features for weld control and programs.74 MPa Plus — Adds push-pull aluminum capabilities. Optimized for use with XMT® MPa,Invision™ MPa and Dimension 650 power sources.

Boom-Style Feeders70 Series Swingarc™ See literature M/13.11Swingarc single and dual boom-mounted wire feeders bring an extra dimension of flexibilityand efficiency to weld stations dealing with large weldments, or wherever operator mobilityis required.

Aluminum Push-Pull Feeders and GunsXR™ Controls See literature M/1.7XR-S Control — Cost-effective push-pull feeder for industrial applications.XR-D Control — Adds capabilities for higher quality welds.

XR-Aluma-Pro™ Gun See literature M/1.71Robust professional grade gun has the highest duty-cycle rating in its class.

XR™-Pistol Gun See literature M/1.73Reliable cost-effective gun for light to medium industrial applications.

XR™-Pistol Pro Gun See literature M/1.74Exceptional aluminum welding results for heavy industrial applications.

Hard Automation70 Series Remote Configurations See literature M/3.0Remote wire feeder control box and wire drive assembly for non-Miller boom applications.

Sub Arc mode provides capability to retrofit into non-digital sub arc applications. See literature no. AY/12.0 for list of compatible accessories. Adapter cord, 115 V for legacy 14-pin accessories is required.

Portable Suitcase-Style FeedersSuitCase® X-TREME™ 8VS and 12VS See literature M/6.42These voltage-sensing feeders are designed to run off of arc voltage from almost anywelding power source. The 8VS utilizes an 8-inch spool of wire and fits through a 14-inch manhole/manway, while the 12VS adds the capability to utilize 12-inch spools andis more commonly used in structural steel and fabrication. ArcReach-equipped modelsprovide remote voltage control of the power source without a cord.

SuitCase® 12RC See literature M/6.45Standard remote voltage control saves the operator a trip back to the power supply forwelding adjustments. For applications where the feeder is within 100 feet of the powersource and control cords are acceptable.

6

Genuine Miller® Accessories

Dimension™ 650 Racks907687 2-pack rack907688 4-pack rack (shown above)Dimension™ 650 ArcReach™ Racks907702 2-pack rack907701 4-pack rackConveniently houses multiple Dimension 650power sources for multiple welders. Featuresinclude:

Provision to parallel power sources oncommon work connections

Two lifting eyes for transportation Rugged skids for dragging or pushing

Dimension™ 650 Running Gear 301307Large rear wheels and front casters provideexcellent power source mobility on the shop floor.Easy to install. Handles double as a cable holder. Note: Does not accommodate gas cylinders, use Running Gear Cylinder Rack 300408 when gas cylinders are required.

Running Gear Cylinder Rack 300408Small footprint and easily maneuverable, withcylinder rack low enough that you do not haveto lift bottles.

GFCI Panel Mount Kit 301179For applications that require GFCI protection ofthe 115-volt receptacle.

Adapter Cord 301259115-volt cord for legacy 14-pin accessories.Required to connect to HDC 1500.

Polarity Control 042871This dual-function control is designed for usewith dual wire feeders or any application whereelectrical isolation and/or polarity reversing ofweld current is required. Both functions can beused at the same time.

Process Control Selector 042872Allows you to easily change weld processeswithout changing cables — from TIG to MIG orTIG to stick. Also includes features of polaritycontrol. Can be used with any constant-current,constant-voltage or multiprocess CC/CV weldingpower source.

Industrial MIG 4/0 Kit 300390Includes Miller flowmeter regulator with 10-foot(3 m) gas hose, 10-foot (3 m) 4/0 feeder weldcable with lugs, and 15-foot (4.6 m) work cablewith 600-amp C-clamp.

HF-251D-1 High-FrequencyArc Starter/Stabilizer042388This portable 250-amp, 60-percent duty cycle unitadds high frequency to the

welding circuit to help start the arc when usingthe TIG (GTAW) process. Operates on 115-volt,50/60/100 Hz. See literature AY/5.1.

Remote Controls and Switches

ArcReach Stick/TIGRemote 301325When paired with an ArcReach powersource, providesremote control of thepower source without a cord — saving time

and money. See literature AY/14.5.

Wireless Remote FootControl 300429For remote current and contactor control.Receiver plugs directly

into the 14-pin receptacle of Miller machine. 90-foot (27.4 m) operating range.

Wireless Remote HandControl 300430For remote current andcontactor control. Receiverplugs directly into the 14-pin receptacle of Miller

machine. 300-foot (91.4 m) operating range.

RFCS-14 Foot Control043554Foot current and contactorcontrol. Includes 20-foot (6 m) cord and 14-pin plug.

RHC-14 Hand Control*242211020 20-foot (6 m) cord242211100 100-foot (30.5 m) cordMiniature hand control

for remote current and contactor control.Dimensions: 4 x 4 x 3.25 inches (102 x 102 x 83 mm). Includes cord and 14-pin plug.*For additional lengths visit MillerWelds.com/equiptoweld

RCC-14 Remote Contactor and Current Control151086East/west rotary-motion finger tip control attachesto TIG torch using two hook-and-loop fasteners.Allows complete current and contactor controlat operator’s fingertips. Includes 26.5-foot (8 m)cord and 14-pin plug.

RCCS-14 Remote Contactor and CurrentControl 043688North/south rotary-motion fingertip controlattaches to TIG torch using two hook-and-loopfasteners. Great for applications that require afiner amperage control. Includes 26.5-foot (8 m)cord and 14-pin plug.

RMLS-14 129337Momentary- and maintained-contact rockerswitch for contactor control. Push forward for maintained contact and backward formomen tary con tact. Includes 26.5-foot (8 m)cord and 14-pin plug.

Extension Cables for 14-Pin Plugs to 14-Pin Sockets*242208025 25 ft. (7.6 m)242208050 50 ft. (15.2 m)242208080 80 ft. (24.4 m)Extension cables make a direct connectionbetween the power source and remote controlor 24 V wire feeder. No messy splicing oradapting required. *For additional lengths visit MillerWelds.com/equiptoweld

Wire Feeders

SuitCase® X-TREME™ 8VS 951582SuitCase® X-TREME™ 12VS 951543Lightweight, portable wire feeder for a variety of wires up to .062 inch. Holds up to an 8-inch(8VS) or 12-inch (12VS) spool of wire. Operateson open-circuit voltage eliminating the need fora control/power cord. Includes Bernard™ BTBGun 300 A. See literature M/6.42.

SuitCase® X-TREME™ 8VS ArcReach951588 With Bernard™ S-Gun™

951584 With Bernard™ BTB Gun 300 ASuitCase® X-TREME™ 12VS ArcReach951589 With Bernard™ S-Gun™

951581 With Bernard™ BTB Gun 300 APortable feeder designed to run off of arcvoltage. When paired with an ArcReach powersources provides remote control of the powersource without a cord — saving time andmoney. See literature M/6.42.

70 Series Wire Feeders S-74 MPa Plus 951291 single feederD-74 MPa Plus 951292 dual feederOrder XR-Aluma-Pro Plus gun and U-grooved driverolls separately to match your aluminum needs. Above models are optimized for Dimension 650 and have push-pull capability.

S-74S 951196 single feeder S-74D 951198 single feederS-74DX 951200 single feederD-74S 951203 dual feeder D-74D 951204 dual feederD-74DX 951206 dual feeder70 Series feeders feature Posifeed™ wire driveassembly and handle a variety of wires. Eachincludes a 15-foot Bernard™ BTB Gun 400 A (two for dual feeders) and .035/.045-inch V-grooved drive rolls. See literature M/3.0.

Welding Intelligence™

Insight Core™ 14-pin Module 301072Easy-to-install module brings Insight Corecapabilities to your existing fleet. This simplified,Internet-based weld data solution collects,transmits and presents actionable information to any Web-connected device. Insight Core canhelp you increase productivity, improve weldquality and manage costs.

Coolant Systems

For more information, see the Coolmate™ Seriesliterature AY/7.2.

Coolmate™ 3 043007 115 V043008 230 VFor use with water-cooled torches rated up to500 amps. Unique paddle-wheel indicator,external filter and easy-fill spout.

Coolmate™ 4 042288 115 VFor use with water-cooled torches rated up to600 amps. Tough molded polyethylene casewith carrying handle.

Coolant 043810Sold in cases of four one-gallon recyclableplastic bottles. Miller coolants contain a base ofethylene glycol and deionized water to protectagainst freezing to -37 degrees Fahrenheit(-38°C) or boiling to 227 degrees Fahrenheit(108°C). Also contains a compound that resistsalgae growth.

7

Genuine Miller® Accessories (Continued)

C

ED

A B

4 holes F

Height: 28.187 in. (716 mm)Width: 16.687 in. (424 mm)Depth: 31.625 in. (803 mm)

Bottom View

A. 16.687 in. (424 mm)B. 14.25 in. (362 mm)C. 30.25 in. (768 mm)D. .687 in. (44 mm)E. 31.625 in. (803 mm)F. .625 in. (17 mm) dia.

Mounting Specifications

Ordering InformationEquipment and Options Stock No. Description Qty. Price

Dimension™ 650 Power Source Only 907617 380/460 V, 50/60 Hz

Dimension™ 650 ArcReach™ 907617001 380/460 V, 50/60 HzPower Source Only

Dimension™ 650 Stationary Package 951638 380/460 V, 50/60 Hz. Includes S-74 MPa Plus feeder, Bernard™ BTB Gun 400 A, .035/.045 drive rolls and industrial MIG 4/0 kit

Dimension™ 650 MIGRunner™ Package 951637 380/460 V, 50/60 Hz. Includes stationary package plus running gear cylinder rack

Dimension™ 650 Rack 907687 2-pack rack 907688 4-pack rack

Dimension™ 650 ArcReach™ Rack 907702 2-pack rack 907701 4-pack rack

Options and Accessories

Dimension 650 Running Gear 301307

Running Gear Cylinder Rack 300408

GFCI Panel Mount Kit 301179

Adapter Cord 301259 115-volt cord for legacy 14-pin accessories. Required to connect to HDC 1500

Polarity Control 042871

Process Control Selector 042872

Industrial MIG 4/0 Kit 300390 Includes flowmeter regulator with 10 ft. (3 m) gas hose, 10 ft. (3 m) 4/0 feeder weld cable with lugs, and 15 ft. (4.6 m) work cable with 600-amp C-clamp

HF-251D-1 Starter/Stabilizer 042388 See literature AY/5.1

Remote Controls

ArcReach™ Stick/TIG Remote 301325 Point-of-use control for stick or TIG welding and gouging with Dimension 650 ArcReach

Wireless Remote Foot Control 300429 Foot control with wireless 90 ft. (27.4 m) operating range

Wireless Remote Hand Control 300430 Hand control with wireless 300 ft. (91.4 m) operating range

RMLS-14 129337 Rocker switch

RCC-14 151086 Fingertip control (east/west)

RCCS-14 043688 Fingertip control (north/south)

RHC-14 242211020 Hand control with 20 ft. (6 m) cord and 14-pin plug 242211100 Hand control with 100 ft. (30.5 m) cord and 14-pin plug

RFCS-14 043554 Foot control

Extension Cables See page 6

Wire Feeders

SuitCase® X-TREME™ 8VS and 12VS See page 7 and literature M/6.42

SuitCase® X-TREME™ Point-of-use control for MIG or flux-cored welding with Dimension 650 ArcReach.8VS and 12VS ArcReach™ See page 7 and literature M/6.42

70 Series See page 7 and See literature M/3.0

SuitCase® 12RC See literature M/6.5

22A See literature M/11.0

24A See literature M/11.0

XR™-Controls See literature M/1.7

XR Push-Pull Guns See literature M/1.71, M/1.73 and M/1.74

Swingarc™ Boom Feeders See literature M/13.11

Welding Intelligence™ See page 7

Coolant Systems See page 7

Date: Total Quoted Price:

© 2016 Miller Electric Mfg. Co.

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